well we cut the plenum behind the glove box... the blend door was laying on its side... so that was definently the problem. I have to order a new door and see if i can fix it. If anyone knows a good place to order a door let me know, i haven't had two seconds to look around yet.

well the heat is FIXED! as stated earlier, i bought the part from the auto store for 10 and change. However putting the blend door in was a pain in the ass! we had to make two cuts into the plastic plenum, one in the front by the heater core and one on the bottom to get the blend door inside the plenum.

The blend door we got was not to factory specifications so we had to take a grinder to the plastic clip peice and probably take it down an 8th of an inch to make it fit the way it needed to. Once we got the blend door in it took us atleast an hour to get the blend door actuator to line up properly with the door.

all i have to say is this thing was a pain in the ass!!!! it took probably 4-5 hours to get this thing in and working! I just duck taped the plenum shut for now, but am considering fiberglassing it after winter is over.

just reading some of these posts. what was the original problem leading to blendoor replacement. i have a 2000 xlt 5.0 and my heat and ac will only blow from the defroster, and a little bit on the feet. were you guys having this same problem?